Optical fiber cable with print protective outer surface profile

ABSTRACT

An optical cable includes a cable body having an outer surface and an inner surface defining a lumen. The cable body has a profile feature formed on the outer surface, wherein the profile feature includes a trough that extends longitudinally between a first buttress and a second buttress, the first buttress and the second buttress having a radial height. The trough defines a continuous concave surface between the first buttress and the second buttress that is recessed below the radial height. An ink layer is adhered to the concave surface, wherein the ink layer forms alphanumeric characters that provide information related to the optical cable.

RELATED APPLICATIONS

This Application is a continuation of U.S. patent application Ser. No.14/193,206, filed on Feb. 28, 2014, which claims the benefit of U.S.Provisional Application No. 61/856,111, filed Jul. 19, 2013, which areincorporated herein by reference in their entirety.

BACKGROUND

The disclosure relates generally to optical communication cables andmore particularly to optical communication cables including a printprotective surface profile. Optical communication cables have seenincreased use in a wide variety of electronics and telecommunicationsfields. Optical communication cables may contain or surround one or moreoptical communication fibers. The cable provides structure andprotection for the optical fibers within the cable.

SUMMARY

One embodiment of the disclosure relates to an optical communicationcable. An optical communication cable including a cable body having anouter surface, an inner surface, a channel defined by the inner surfaceand a longitudinal axis extending through the center of the channel. Theouter surface of the cable body defines a profile feature such that theouter surface at the profile feature is asymmetric about thelongitudinal axis. The profile feature having at least two peaks and atleast one trough between the peaks, and the profile feature extendsaxially along at least a portion of the length of the outer surface ofthe cable body. The cable includes an optical transmission elementlocated in the channel, and an ink layer positioned along an outersurface of the trough of the profile feature. The peaks are configuredto limit contact of the ink layer with surfaces during installation andthereby act to protect the ink layer from abrasion.

An additional embodiment of the disclosure relates to an optical cable.The optical cable includes a cable body having an outer surface and alongitudinal axis, and the cable includes an optical transmissionelement located within the cable body. The cable includes an array ofgrooves formed in the outer surface of the cable, and each groove of thearray includes a lower surface recessed below an outermost surface ofthe cable. The grooves of the array are positioned in a non-parallelposition relative to the longitudinal axis of the cable body. The cableincludes an ink indicia layer positioned on the outer surface of thecable body, and a portion of the ink indicia layer is adhered to thelower surface of at least one groove of the array of grooves.

An additional embodiment of the disclosure relates to a method offorming an optical cable with a print protecting outer surface. Themethod includes extruding a cable body over an optical fiber, and thecable body has an outer surface. The method includes applying an inklayer forming indicia to the outer surface of the cable body. The methodincludes contacting the outer surface of the cable body with a tool atthe position of the ink layer to deform the outer surface of the cablebody forming an profile feature in the outer surface of the cable body,and the ink layer is located within profile feature.

An additional embodiment of the disclosure relates to a method offorming an optical cable with a print protecting outer surface. Themethod includes extruding a cable body over an optical fiber, and thecable body has an outer surface. The method includes forming a profilefeature by mechanically deforming the cable body following extrusion.The profile feature having a trough recessed below the outer surface ofthe cable body, and the profile feature extends axially along at least aportion of the length of the outer surface of the cable body. The methodincludes applying an ink layer forming indicia to a surface of thetrough.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from the description or recognized by practicing theembodiments as described in the written description and claims hereof,as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understand the natureand character of the claims.

The accompanying drawings are included to provide a furtherunderstanding and are incorporated in and constitute a part of thisspecification. The drawings illustrate one or more embodiment(s), andtogether with the description serve to explain principles and operationof the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an optical fiber cable according to anexemplary embodiment.

FIG. 2 is a detailed perspective view of a portion of the optical fibercable of FIG. 1 according to an exemplary embodiment.

FIG. 3 is a cross-sectional view of the optical fiber cable of FIG. 1according to an exemplary embodiment.

FIG. 4 is a detailed cross-sectional view of a portion of the opticalfiber cable of FIG. 1 according to an exemplary embodiment.

FIG. 5 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 6 is a detailed perspective view of a portion of the optical fibercable of FIG. 5 according to an exemplary embodiment.

FIG. 7 is a cross-sectional view of the optical fiber cable of FIG. 5according to an exemplary embodiment.

FIG. 8 is a detailed cross-sectional view of a portion of the opticalfiber cable of FIG. 5 according to an exemplary embodiment.

FIG. 9 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 10 is a detailed perspective view of a portion of the optical fibercable of FIG. 9 according to an exemplary embodiment.

FIG. 11 is a cross-sectional view of the optical fiber cable of FIG. 9according to an exemplary embodiment.

FIG. 12 is a detailed cross-sectional view of a portion of the opticalfiber cable of FIG. 9 according to an exemplary embodiment.

FIG. 13 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 14 is a detailed perspective view of a portion of the optical fibercable of FIG. 13 according to an exemplary embodiment.

FIG. 15 is a cross-sectional view of the optical fiber cable of FIG. 13according to an exemplary embodiment.

FIG. 16 is a detailed cross-sectional view of a portion of the opticalfiber cable of FIG. 13 according to an exemplary embodiment.

FIG. 17 is a detailed cross-section view of the optical fiber cable ofFIG. 13 showing an ink layer within grooves of a protection profileaccording to an exemplary embodiment.

FIG. 18 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 19 is a detailed perspective view of a portion of the optical fibercable of FIG. 18 according to an exemplary embodiment.

FIG. 20 is a cross-sectional view of the optical fiber cable of FIG. 18according to an exemplary embodiment.

FIG. 21 is a detailed cross-sectional view of a portion of the opticalfiber cable of FIG. 18 according to an exemplary embodiment.

FIG. 22 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 23 is a cross-sectional view of the optical fiber cable of FIG. 22according to an exemplary embodiment.

FIG. 24 is a detailed cross-sectional view of a portion of the opticalfiber cable of FIG. 22 according to an exemplary embodiment.

FIG. 25 is a longitudinal cross-sectional view of the optical fibercable of FIG. 22 according to an exemplary embodiment.

FIG. 26 is a detailed cross-section view of a portion the view shown inFIG. 25 according to an exemplary embodiment.

FIG. 27 is a detailed perspective view of a portion of the optical fibercable of FIG. 22 showing an ink layer located on a profile featureaccording to an exemplary embodiment.

FIG. 28 is a detailed perspective view of a portion of the optical fibercable of FIG. 22 showing the remaining portion of an ink layer within aprofile feature following wear according to an exemplary embodiment.

FIG. 29 shows a system forming a fiber optic cable with a printprotective surface profile according to an exemplary embodiment.

FIG. 30 shows a system forming a fiber optic cable with a printprotective surface profile according to an exemplary embodiment.

FIG. 31 is a representative view of a print protection profile followingapplication of an ink layer according to an exemplary embodiment.

FIG. 32 is a representative view of a print protection profile followingwear of outer portions of an ink layer according to an exemplaryembodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of an opticalcommunication cable are shown. In general, the cable embodimentsdisclosed herein include a surface-applied ink layer (e.g., an ink jetdeposited ink layer) adhered to the outer surface of the body of thecable. To protect the surface-applied ink layer, the cable embodimentsdisclosed herein include a profile feature formed in the outer surfaceof the cable body that acts to protect the ink layer. Specifically, theprofile feature may include a recess, groove or trough that has asurface that is located below the outer surface of the cable bodyadjacent to the recess, groove or trough. The recession of the ink andthe material of the cable defining the outermost surfaces of the cablebody adjacent the ink layer act as a buffer that limits contact of theink layer with various surfaces during use or installation. By limitingthe contact experienced by the ink layer, the profile feature acts toprotect the ink layer from being damaged, abraded or worn off during theinstallation or use of the cable while still allowing the user to viewthe ink layer.

During a hot foil printing process (a typical printing process used formany fiber optic cables), the hot foil applied ink is embedded below theouter surface of the cable body due to the heating of the ink layer. Incontrast to hot foil printing, a surface applied ink layer (e.g., an inkjet applied ink layer) is located on the outer surface of the cable bodyand thus, may be more susceptible to damage or wear during installation.The cable embodiments discussed herein include a formed surface profilefeature with at least one recess or trough below the outer surface ofthe cable body such that the surface applied ink layer with the troughis located below the outer most surfaces of the cable body. Further, theprofile features disclosed herein are localized profiles at the positionof the ink layer such that the outer surface or perimeter of the cablebody is asymmetrical about the longitudinal axis of the cable body(e.g., the profile feature is not a repeating pattern formed around theentire perimeter or circumference of the cable body). The asymmetry ofthe profile feature provides a tactile indicator that may assist duringinstallation or repair by allowing the user to identify the location ofthe ink layer by touch which allows the user to more easily/efficientlyreorient the cable to view the ink layer. This can be particularlyuseful when working with an installed cable in tightly packed, confinedand/or poorly lit areas.

Referring to FIGS. 1-4, an optical communication cable, shown as cable10, is shown according to an exemplary embodiment. Cable 10 includes acable body, shown as cable jacket 12, and an indicia layer, shown as inklayer 14. Generally, ink layer 14 is deposited to form alphanumericcharacters to provide various information regarding cable 10 (e.g.,brand, size, cable type, etc.) or other non-alphanumeric indicia (e.g.,measurement marks, ID color, etc.) In one embodiment, ink layer 14 maybe formed from a white, titanium oxide based ink. In other embodiments,dye based inks of other colors (e.g., yellow, orange, red, etc.) canused particularly for cables in which the color of the cable jacket is anon-black color.

Cable jacket 12 has an outer surface 16 and an inner surface 18 thatdefines a channel or lumen 20. Generally, lumen 20 extends the length ofcable jacket 12 between openings at opposing ends of cable 10. One ormore optical transmission elements, shown as fiber optic ribbon 22, arelocated within lumen 20. In various embodiments, fiber optic ribbon 22includes one or more optical fibers, and each optical fiber includes anoptical core, a cladding layer surrounding the optical core and an outerprotective layer (e.g., a polymer coating layer) surrounding the opticalcore and the cladding layer. In other embodiments, the opticaltransmission element may be one or more multi-core optical fibers. Inthese embodiments, multiple optical fibers (or multiple optical cores inthe case of multi-core optical fibers) are located within the lumen 20of cable 10. In various embodiments, as shown in FIG. 3, a gap or spacemay be present between the outer surface of ribbon 22 and inner surface18 which allows for the positioning and realignment of ribbon 22 withincable 10 as cable 10 is moved and positioned during installation or inuse. In various embodiments, cable jacket 12 may have a thicknessbetween 0.5 mm and 5.0 mm.

In general, cable 10 provides structure and protection to fiber opticribbon 22 during and after installation (e.g., protection duringhandling, protection from elements, vermin, etc.). In one embodiment,cable jacket 12 is formed from a single layer of extruded polymermaterial (e.g., a medium-density polyethylene material), and in otherembodiments, cable jacket 12 may include multiple layers of materialswhere the outermost layer defines the outer surface of cable jacket 12.Further, cable 10 may include one or more strengthening member embeddedwithin the material of cable jacket 12. For example, cable 10 mayinclude an elongate strengthening member (e.g., a fiber or rod) thatruns the length of cable jacket 12 and that is formed from a materialthat is more rigid than the material of cable jacket 12. In variousembodiments, the strengthening member is metal, braided steel, glassreinforced plastic, fiber glass, fiber glass yarns or other suitablematerial.

Cable 10 includes a profile feature that acts to protect ink layer 14.Generally the profile feature is a shape, texture or pattern formed inouter surface 16 of cable jacket 12 that is located at the position ofthe ink layer. In the embodiment of FIGS. 1-4 the profile featureincludes a first peak defined by buttress 24 and a second peak definedby buttress 26. A trough 28 is located between buttresses 24 and 26 suchthat the outer surface 32 of trough 28 is recessed below the outermostsurfaces of buttresses 24 and 26.

As shown, buttresses 24 and 26 generally are raised ridges that extendradially outward from the generally cylindrical outer surface 16 ofcable jacket 12. In the embodiment shown, buttresses 24 and 26 aresubstantially parallel ridges or projections that extend axially alongat least a portion of the length of cable jacket 12. Further, as shownin FIG. 3, buttresses 24 and 26 and trough 28 are located centeredaround the 12 o'clock position in the orientation of FIG. 3. Thus, thelocalized positioning of buttresses 24 and 26 and trough 28 results inthe outer perimeter and outer surface of cable jacket 12 that isasymmetrical about the longitudinal axis 30 of lumen 20 as shown in FIG.3. As noted above, this asymmetry acts as a tactile identificationfeature that identifies the position of ink layer 14 along the surfaceof cable jacket 12.

Trough 28 includes an outer surface 32 that is located betweenbuttresses 24 and 26. Ink layer 14 is adhered to the outer surface 32 oftrough 28 such that ink layer 14 is located between buttresses 24 and 26and below the outermost surfaces of buttresses 24 and 26. As shown, inklayer 14 forms alphanumeric characters that provides information relatedto the cable. In various embodiments, the information may include sourceidentifying information, measurement marks, identification regarding theoptical fibers within the cable, etc.

As shown best in FIGS. 2 and 4, in the embodiment shown, ink layer 14 isa surface deposited ink layer adhered or bonded to outer surface 32 oftrough 28. Thus, ink layer 14 extends outward from the outer surface 32of trough 28. Generally, the outermost surface of ink layer 14 is aboveouter surface 32 of trough 28 but is below the outermost surface ofbuttresses 24 and 26. In the circular cross-sectional shaped embodimentof FIGS. 1-4, the radius measured at the outermost surface of ink layer14 is greater than the radius measured at the outermost portion of outersurface 32. However, because the outermost surface of ink layer 14 isbelow the outermost surface of buttresses 24 and 26, buttresses 24 and26 act to limit the direct contact ink layer 14 has with surfaces andobjects (e.g., the surfaces of ducts receiving cable 10) duringinstallation and in use, and as such, the profile acts to limit theamount of ink layer 14 that may be worn off during installation and inuse.

In one embodiment, ink layer 14 is an ink jet deposited ink layer. Insuch embodiments, charged ink particles are sprayed from an ink jetnozzle to form the desired indicia (e.g., alphanumeric indicia, othertypes of indicia) of ink layer 14. In certain embodiments, cable jacket12 is formed from a non-polar material (e.g., a polyethylene material)that does not readily accept bonding of the charged ink jet droplets. Insuch embodiments, cable jacket 12 may be polarized (e.g., oxidized) byplasma treatment to create a surface that wets/bonds with the liquid inkjet droplets. In various embodiments, ink layer 14 is formed usingsolvent-based pigmented inks or UV curable pigmented inks. In otherembodiments, ink layer 14 is formed through other ink deposition orprinting techniques such as low indentation hot foil printing. In otherembodiments, the alphanumeric characters of ink layer 14 may be formedusing laser activated dyes. In yet other embodiments, cable 10 mayinclude a non-ink based indicia layer. For example, the indicia layermay be an etched or embossed indicia layer, a surface adhered label, orlaser ablation of carbon black within cable jacket 12 and subsequentfoaming of the material of cable jacket 12 to create the contrast toform indicia.

In various embodiments, the relative sizing of ink layer 14 and theprofile feature are selected to provide sufficient protection for inklayer 14. As shown in FIG. 4, ink layer 14 has a thickness shown asdimension A, and the profile feature has a depth B which is the distancebetween the outer most surface of buttresses 24 and 26 and outer surface32 of trough 28. In various embodiments, thickness A of ink layer 14 isbetween 1% and 20% of depth B. In various embodiments, depth B isbetween 5 micrometers and 300 micrometers. In such embodiments, thethickness A of ink layer 14 is between 0.5 micrometers and 10micrometers, specifically between 1 micrometers and 5 micrometers, andmore specifically is about 3 micrometers. The thicknesses and depthsdiscussed herein are generally the dimension of the layers measured inthe radial dimension for the circular cross-sectional shaped cableembodiments specifically disclosed, but for embodiments having othercross-sectional shapes, the thicknesses discussed herein may generallybe the dimension measured between inner and outer surfaces of theparticular layer.

As shown in FIG. 4, the distance between the outermost point of buttress24 and the outermost point of buttress 26 is shown as dimension W1, andthe width (i.e., the circumferential dimension in the cylindricalembodiment of FIG. 4) of ink layer 14 is shown as dimension W2. Ingeneral, W1 is selected to be large enough to allow ink layer 14 to havea sufficient width W2 such that the ink layer is legible. However, W1 isalso sized relative to profile depth B and ink layer width W2 to providesufficient effective protection to ink layer 14. In various embodiments,the length W1 is between 3 mm and 5 mm. In other embodiments, length W1is between 105% and 150% of the W2 of ink layer 14, and morespecifically length W1 is between 110% and 130% of the W2 of ink layer14. In another embodiment, length W1 is between 10 times and 2000 timesthe profile depth B, and more specifically is between 15 times and 1000times the profile depth B.

In various embodiments, cable jacket 12 is an extruded thermoplasticmaterial. In a specific embodiment, the material of cable jacket 12 is amedium-density polyethylene based material. In various otherembodiments, cable jacket 12 may be a variety of materials used in cablemanufacturing such as polyvinyl chloride (PVC), polyvinylidenedifluoride (PVDF), nylon, polyester or polycarbonate and theircopolymers. In addition, the material of cable jacket 12 may includesmall quantities of other materials or fillers that provide differentproperties to the material of cable jacket 12. For example, the materialof cable jacket 12 may include materials that provide for coloring,UV/light blocking (e.g., carbon black), burn resistance, etc.

Referring to FIGS. 5-8, an optical communication cable 50 is shownaccording to an exemplary embodiment. Cable 50 is substantially the sameas cable 10 except that cable 50 includes a profile feature thatincludes a trough shown as recess 52. Generally, recess 52 is adepression formed in cable jacket 12. Recess 52 includes an outersurface 54 and sidewalls 56 and 58. Ink layer 14 is positioned on outersurface 54 of recess 52. Generally, recess 52 is a localized depressionlocated centered around the 12 o'clock position in the orientation ofFIG. 7. Thus, the localized positioning of recess 52 results in theouter perimeter and surface of cable jacket 12 that is asymmetricalabout the longitudinal axis 30 of lumen 20 as shown in FIG. 7. Recess 52is a localized decrease in the outer diameter of the otherwise generallycylindrical outer surface 16.

Sidewall 56 extends outward away from outer surface 54 defining a peakof the profile feature where sidewall 56 joins to outer surface 16 ofcable jacket 12. Thus, in this embodiment, the outer diameters at theouter most portion of sidewalls 56 and 58 are substantially the same asthe outer most diameter of the generally cylindrical outer surface 16 ofcable 50. Sidewall 58 is on the other side of outer surface 54 andextends outward away from outer surface 54 defining a second peak of theprofile feature where sidewall 56 joins to outer surface 16 of cablejacket 12. As shown, sidewalls 56 and 58 are angled away from outersurface 54, such that the angle between outer surface 54 and sidewalls56 and 58 is greater than 90 degrees, and more specifically is between120 degrees and 140 degrees. Recess 52 generally includes a depth C anda width W1, as discussed above, and ink layer 14 includes a thickness A,as discussed above. In various embodiments depth C is the same as thevarious embodiments of depth B discussed above.

Referring to FIGS. 9-12, an optical communication cable 70 is shownaccording to an exemplary embodiment. Cable 70 is substantially the sameas cable 10 except that cable 70 includes a profile feature thatincludes a plurality of ridges 72 that extend radially outward from thegenerally cylindrical outer surface 16 of cable jacket 12 such that theoutermost surface of ridges 72 is located above the outermost surface 16of cable jacket 12. In the embodiment shown, ridges 72 are substantiallyparallel ridges that extend axially along at least a portion of thelength of cable jacket 12. A trough 74 is located between each of theadjacent ridges 72. Ink layer 14 is adhered to the outer surface 76 ofeach trough 74. In this embodiment, the profile feature includes morethan two peaks and multiple troughs, and the portions of ink layer 14that contribute to a single alphanumeric character are located on morethan one trough 74 and span more than one ridge 72. In variousembodiments, the amount or proportion of ink layer 14 that is locatedwithin troughs 74 is greater than the amount or proportion of ink layer14 that is located on the outer surfaces of ridges 72.

Ridges 72 and troughs 74 are localized, centered around the 12 o'clockposition in the orientation of FIG. 11. Thus, the localized positioningof ridges 72 results in the outer perimeter and surface of cable jacket12 that is asymmetrical about the longitudinal axis 30 of lumen 20 asshown in FIG. 11. As noted above, this asymmetry acts as a tactileidentification feature that identifies the position of ink layer 14 onthe of cable jacket 12.

The profile feature of FIGS. 9-12 has a depth D, which is the distancebetween the outer most surfaces of ridges 72 and outer surface 76 of theadjacent trough 74. In various embodiments depth D is the same as thevarious embodiments of depth B discussed above, and ink layer 14includes a thickness A as discussed above. Ridges 72 are also evenlyspaced from one another, and in the embodiment shown, a width W3 is thedistance between the outer most point of each adjacent ridge 72. Invarious embodiments, W3 is between 0.1 mm and 1.0 mm and morespecifically is between 0.2 mm and 0.5 mm.

Referring to FIGS. 13-17, an optical communication cable 80 is shownaccording to an exemplary embodiment. Cable 80 is substantially the sameas cable 10 except that cable 80 includes a profile feature thatincludes an array of grooves 82 formed in outer surface 16 of cablejacket 12. Groove array 82 extends axially along at least a portion ofthe length of cable jacket 12. Groove array 82 is located centeredaround the 12 o'clock position in the orientation of FIG. 15. Thus, thelocalized positioning of groove array 82 results in the outer perimeterand surface of cable jacket 12 that is asymmetrical about thelongitudinal axis 30 of lumen 20 as shown in FIG. 15. As noted above,this asymmetry acts as a tactile identification feature that identifiesthe position of ink layer 14 along the surface of cable jacket 12.

Array of grooves 82 includes a first set of parallel grooves 84 thatincludes a plurality of individual grooves 86, and array of grooves 82includes a second set of parallel grooves 88 that includes a pluralityof individual grooves 90. Grooves 86 and grooves 90 are positioned at anon-parallel (i.e., non-zero angle) relative to longitudinal axis 30. Inthe embodiment of FIGS. 13-17, grooves 86 are positioned at about a 45degree angle to longitudinal axis 30, and grooves 90 are positioned atabout a 45 degree angle to longitudinal axis 30, in the oppositedirection. Grooves 86 and grooves 90 are also positioned at anon-parallel (i.e., non-zero angle) relative to each other. In thisembodiment, grooves 86 are positioned at about a 90 degree anglerelative to grooves 90.

Each groove 86 and 90 defines a trough having a lower surface and peakslocated on either side of the trough. In this arrangement, the troughsof grooves 86 are positioned at an angle relative to the troughs ofgrooves 90 resulting in a cross-hatched pattern of troughs and ridges asshown in FIG. 14. In this embodiment, ink layer 14 is adhered to theouter surface of cable jacket 12 over groove array 82 such that portionsof the ink layer are located on the outer surface of the bottom of thegrooves, the groove sidewalls and the outer surfaces between thegrooves. As shown for example in FIG. 17, portions of ink layer 14 areshown extending into grooves 90 such that the ink is adhered to theouter surface of the trough formed by the groove, and portions of inklayer 14 are located on the outermost surface portions 92 of groovearray 82 that are located between grooves 90. The portions of ink layer14 that contribute to a single alphanumeric character span multiplegrooves as shown in FIG. 14. In this embodiment, sufficient amounts ofink layer 14 are located within grooves 86 or 90 such that thealphanumeric characters remain legible even if the portions of ink layer14 on the outermost surface portions 92 between grooves 90 is worn off.

In various embodiments, grooves 86 and 90 have a depth between 5micrometers and 300 micrometers. In addition, in various embodiments thespacing between grooves 86 of first set of grooves 84 and the spacingbetween grooves 90 of second set of grooves 86 is selected such that asufficient amount of ink layer 14 is located within the grooves tomaintain legibility if the portions of ink layer 14 on the outermostsurfaces between grooves is worn off. In various embodiments, thespacing between adjacent grooves 90 and adjacent grooves 86 are the sameand are shown by the dimension E. In various embodiments, dimension E isbetween 0.05 mm and 0.5 mm, and more specifically between 0.1 mm and 0.3mm.

Referring to FIGS. 18-21, an optical communication cable 96 is shownaccording to an exemplary embodiment. Cable 96 is substantially the sameas cable 10 except that cable 96 includes groove array 82 formed in theouter surface 32 of trough 28. In this embodiment, buttresses 24 and 26act to limit abrasion of ink layer 14 as discussed above regarding theembodiment of FIGS. 1-4, and groove array 82 provides further protectionfor the portions of ink layer 14 located within the grooves of groovearray 82 as discussed above regarding the embodiments of FIGS. 13-17.

Referring to FIGS. 22-28, an optical communication cable 100 is shownaccording to an exemplary embodiment. Cable 100 is substantially thesame as cable 10 except as discussed herein. Cable 100 includes an inkprotection profile feature that includes a first peak defined bybuttress 102 and a second peak defined by buttress 104. A trough 106 islocated between buttresses 102 and 104 such that the outer surface 108of trough 106 is recessed below the outermost surfaces of buttresses 102and 104.

As shown, buttresses 102 and 104 are raised ridges that extend radiallyoutward from the generally cylindrical outer surface 16 of cable jacket12. In the embodiment shown, buttresses 102 and 104 are substantiallyparallel ridges or projections that extend axially along at least aportion of the length of cable jacket 12. Further, as shown in FIG. 23,buttresses 102 and 104 and trough 106 are located centered around the 12o'clock position in the orientation of FIG. 23. Thus, the localizedpositioning of buttresses 102 and 104 and trough 106 results in theouter perimeter and surface of cable jacket 12 that is asymmetricalabout the longitudinal axis 30 of lumen 20 as shown in FIG. 23. As notedabove, this asymmetry acts as a tactile identification feature thatidentifies the position of ink layer 14 along the surface of cablejacket 12.

Trough 106 includes an outer surface 108 that is located betweenbuttresses 102 and 104. Ink layer 14 is adhered to the outer surface 108of trough 106 such that ink layer 14 is located between buttresses 102and 104 and below the outermost surfaces of buttresses 102 and 104. Asshown best in FIG. 24, outer surface 108 of trough 106 is primarily aconcave surface, and in the embodiment shown is a continuous curvedsurface extending between buttresses 102 and 104. In variousembodiments, outer surface 108 has a radius of curvature between 3 mmand 10 mm, and more specifically, between 4 mm and 6 mm.

As shown in FIG. 24, the distance between the outermost point ofbuttress 102 and the outermost point of buttress 104 is shown asdimension W4, and the width of ink layer 14 is shown as dimension W2.Further, the profile feature has a depth F, which is the distancebetween the lowest point of trough 106 and the outermost point ofbuttress 102 or 104. In general, W4 is selected to be large enough toallow ink layer 14 to have a sufficient width W2 such that ink layer 14is legible, and W4 is also sized relative to profile depth F to providesufficient protection to ink layer 14. In various embodiments, thelength W4 is between 3 mm and 5 mm. In other embodiments, length W4 isbetween 105% and 150% of the W2 of ink layer 14, and more specificallylength W4 is between 110% and 130% of the W2 of ink layer 14. In anotherembodiments, length W4 is between 5 times and 25 times the profile depthF, and more specifically is between 10 times and 20 times the profiledepth F.

In addition, the print protection profile of cable 100 includes a groovearray 110 located on outer surface 108 of trough 106. Groove array 110includes a plurality of parallel grooves 112 that are positioned at anon-parallel angle relative to longitudinal axis 30. In the embodimentshown, grooves 112 of groove array 110 are substantially perpendicularto longitudinal axis 30 and are substantially perpendicular tobuttresses 102 and 104. As shown in FIGS. 25 and 26, each groove 112includes peaks 114 located on opposite sides of a groove trough 116.Each groove 112 includes groove sidewalls 118 that extend between groovetrough 116 and peaks 114. As shown in FIG. 26, grooves 112 are shapedsuch that the profile of each groove 112 is a continuously curvedpattern of alternating peaks 114 and troughs 116 joined by sidewalls118.

As shown in FIGS. 27 and 28, ink layer 14 may be formed from a series ofink dots 120 that are located between buttresses 102 and 104. Ink dots120 are adhered to the outer surface of cable jacket 12 over groovearray 110 such that various ink dots are located on the surfaces of thegroove troughs 116, the groove sidewalls 118 and the outer surfaces ofgroove peaks 114. The ink dots 120 that contribute to a singlealphanumeric character span multiple grooves 112 as shown in FIG. 27. Inthis embodiment, sufficient numbers of ink dots 120 are located withingrooves 112 (e.g., on the outer surface of groove troughs 116 or ongroove sidewalls 118) such that the alphanumeric characters remainlegible even if the portions of ink dots 120 on the outermost surfacesbetween grooves are worn off, as shown at 122 in FIG. 28.

Grooves 112 include a groove depth G which is the distance between theinnermost point in groove trough 116 and the outermost point of groovepeak 114. In various embodiments, groove depth G is between 0.05 mm and0.2 mm. Grooves 112 also include groove spacing H which is the distancebetween the outer most points of adjacent groove peaks 114. In variousembodiments, groove spacing H is between 0.1 mm and 0.3 mm. As shown inFIG. 26, grooves 112 are recessed below the outermost surface ofbuttresses 102 and 104, shown by the dimension J. In variousembodiments, J is between 0.05 mm and 0.1 mm. In these embodiments, withgrooves 112 recessed below the outermost surface of buttresses 102 and104, buttresses 102 and 104 act to protect ink layer 14 from severeabrasion that may be caused by contact with larger structures andsurfaces during the installation process, and grooves 112 may act toprotect the portions of ink layer 14 located within the grooves frommilder abrasion that may be caused by contact with dirt, dust, etc.during installation.

Referring to FIG. 29, a system 150 for forming a fiber optic cable witha print protective surface profile and related method is shown accordingto an exemplary embodiment. Generally system 150 is configured to applyan ink layer onto an extruded cable body and then to form the printprotection profile over the deposited ink layer.

First, a cable body is extruded over the optical fibers to create acable, such as cable 10 discussed above. Following extrusion, theextruded cable body, such as cable jacket 12, traverses system 150 inthe direction shown by arrow 152. At stage 154, cable jacket 12 passesthrough an ink applicator, shown as ink jet printer head 156. Ink jetprinter head 156 deposits ink layer 14 onto outer surface 16 of cablejacket 12. In one embodiment, a pretreatment device 158 may be used tomodify the material of cable jacket 12 to better adhere ink jetdeposited ink layer 14. In one embodiment, pretreatment device 158 maybe a plasma treatment device that oxidizes/polarizes outer surface 16 ofcable jacket 12 to create a surface that the ink jet droplets from inkjet printer head 156 wet/adhere to. At stage 160, cable jacket 12 isheated by heating device 162. Heating device 162 softens the material ofcable jacket 12 to facilitate formation of a surface profile at stage164.

At stage 164, an embossing device 166 engages cable jacket 12 at theposition of the deposited ink layer 14. Embossing device 166mechanically deforms cable jacket 12 as embossing device 166 engages theheated cable jacket. In various embodiments, embossing device 166includes a surface with a profile complimentary to the print protectionprofile to be formed in cable jacket 12, and as the profile of embossingdevice 166 engages cable jacket 12, embossing device 166 imprints cablejacket 12 with the desired profile. As shown at stage 168, becauseembossing device 166 engages cable jacket 12 after deposition of inklayer 14, embossing device 166 acts to push ink layer 14 into theprotection profile such that ink layer 14 is recessed at least partiallybelow the outermost surface of cable jacket 12.

In one embodiment, embossing device 166 may be a roller wheel thatrotates as cable jacket 12 moves past station 164. In one embodimentembossing device 166 may have a heated outer surface to further assistin the formation of the profile in the surface of cable jacket 12.Embossing device 166 may be shaped and configured to produce any of theprint protection profiles discussed herein.

Referring to FIGS. 30-32, a system 200 for forming a fiber optic cablewith a print protective surface profile and related method is shownaccording to an exemplary embodiment. Generally, system 200 isconfigured to form the print protection profile prior to deposition ofthe ink layer, then to deposit the ink layer onto the print protectionprofile. First, a cable body is extruded over the optical fibers tocreate a cable, such as cable 10 discussed above. Following extrusion,the extruded cable body, such as cable jacket 12, traverses system 200in the direction shown by arrow 202. At stage 204, an embossing device206 engages cable jacket 12 to form an asymmetrical print protectionprofile 208 in outer surface 16 of cable body 12. Embossing device 206mechanically deforms cable body 12 as embossing device 206 engages thecable jacket. In various embodiments, embossing device 206 includes asurface with a profile complimentary to the print protection profile tobe formed in cable jacket 12, and as the profile of embossing device 206engages cable jacket 12 embossing device imprints cable jacket 12 withthe desired profile. In one embodiment, embossing device 206 is a heatedembossing wheel that rotates to engage outer surface 16 of cable jacket12, and this contact in turn deforms the material of cable jacket 12forming the desired print protection profile. In another embodiment, theprint profile formation device may mechanically deform the surface ofthe cable body by removing material (e.g., scraping or etching) to formthe print protection profile.

At stage 210, cable jacket 12 passes through an ink applicator, shown asink jet printer head 212. Ink jet printer head 212 deposits ink layer 14onto outer surface 16 of cable jacket 12 at the position of printprotection profile 208. In one embodiment, a pretreatment device 214 maybe used to modify the material of cable jacket 12 to better wet/adhereink jet deposited ink layer 14 prior to ink layer deposition. In oneembodiment, pretreatment device 214 may be a plasma treatment devicethat oxidizes/polarizes surface 16 of cable jacket 12 to create asurface that the charged ink jet droplets from ink jet printer head 212adhere to. As shown schematically in FIG. 31, application of ink layer14 over profile 208 results in portions 220 of ink layer 14 located bothwithin troughs 222 and on peaks 224. As shown schematically in FIG. 32,if abrasion occurs, certain portions of ink layer 14 may be lostexposing additional peaks 224. However, because sufficient ink portions220 are located within troughs 222 the alphanumeric characters or otherindicia formed by ink layer 14 remains legible.

While the specific cable embodiments discussed herein and shown in thefigures relate primarily to cables that have a substantially circularcross-sectional shape defining substantially cylindrical internallumens, in other embodiments, the cables discussed herein may have anynumber of cross-section shapes. For example, in various embodiments,cable jacket 12 may have a square, rectangular, triangular or otherpolygonal cross-sectional shape. In such embodiments, the passage orlumen of the cable may be the same shape or different shape than theshape of cable jacket 12. In some embodiments, cable jacket 12 maydefine more than channels or passages. In such embodiments, the multiplechannels may be of the same size and shape as each other or may eachhave different sizes or shapes.

The optical fibers discussed herein may be flexible, transparent opticalfibers made of glass or plastic. The fibers may function as a waveguideto transmit light between the two ends of the optical fiber. Opticalfibers may include a transparent core surrounded by a transparentcladding material with a lower index of refraction. Light may be kept inthe core by total internal reflection. Glass optical fibers may comprisesilica, but some other materials such as fluorozirconate,fluoroaluminate, and chalcogenide glasses, as well as crystallinematerials, such as sapphire, may be used. The light may be guided downthe core of the optical fibers by an optical cladding with a lowerrefractive index that traps light in the core through total internalreflection. The cladding may be coated by a buffer and/or anothercoating(s) that protects it from moisture and/or physical damage. Thesecoatings may be UV-cured urethane acrylate composite materials appliedto the outside of the optical fiber during the drawing process. Thecoatings may protect the strands of glass fiber.

Some or all of the following may be expressly, impliedly, or inherentlydisclosed above and/or in the Figures.

In contemplated embodiments, the surface of the surface profile may beroughened, such as with a texturing device, such as brass brush, asander drum (e.g., using size 40 grit), a wire brush when or otherdevices. The process that roughens the surface may form a recess asdisclosed above. On a micro-scale, the roughened surface is scored withgrooves that have local troughs and peaks, as disclosed above, whererubbing contact may not remove ink located in the grooves of theroughened surface.

In contemplated embodiments, additional processes may be used incombination with the surface profile to improve bonding of the ink tothe surface of the cable body. In some such embodiments, the surface ofthe cable body may be treated with plasma or flame to increase surfaceactivation, thereby at least partially mitigating poor bonding qualitiesof jacket materials disclosed above, such as non-polar materials, suchas polyethylene. In other such embodiments, bonding additives (e.g.,maleic anhydride copolymer, ethylene acrylic acid copolymer, etc.) maybe compounded into the jacket or applied to the surface thereof (e.g.,tie layer) prior to application of the ink layer.

Similar to the embodiment shown in FIG. 14, in contemplated embodiments,the surface profile may include a dimpled surface, where the peaks shownin FIG. 14 are instead recesses in which to hold ink. In some suchembodiments, the dimples may not be in a repeating pattern, but mayinstead be no-periodic, such as to increase protection of theintermeshed ink from otherwise wearing contact along a wide range ofdifferent directions.

Accordingly, any of the surface profile geometries disclosed herein maybe arranged in non-repeating and/or non-periodic patterns within aprofile feature localized to particular an ink layer. Similarly discretesurface profile geometries along the length of a particular opticalcable may differ from one another in terms of the specific geometry ofthe respective profile feature. In some such embodiments, an ink layerin one part of the optical cable may have a profile feature similar tothat shown in FIG. 10, while an ink layer in another part of the samecable may have a profile feature similar to that of FIG. 14, and yetanother ink layer in a third part of the optical cable may have aprofile feature similar to that shown in FIG. 22, but without buttresses102, 104, similar to the profile feature of FIG. 14, which does notinclude buttresses.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is in no way intendedthat any particular order be inferred.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the disclosed embodiments. Since modificationscombinations, sub-combinations and variations of the disclosedembodiments incorporating the spirit and substance of the embodimentsmay occur to persons skilled in the art, the disclosed embodimentsshould be construed to include everything within the scope of theappended claims and their equivalents. As will be understood by those ofordinary skill in the art, features and attributes associated withembodiments shown in one of the Figures or described in the textrelating to one of the embodiments may well be applied to otherembodiments shown in another of the Figures and/or described elsewherein the text.

What is claimed is:
 1. An optical cable, comprising: a cable body havingan outer surface and an inner surface defining a lumen, wherein thecable body has a profile feature formed on the outer surface, whereinthe profile feature comprises a trough that extends longitudinallybetween a first buttress and a second buttress, the first buttress andthe second buttress having a radial height, and wherein the troughdefines a continuous concave surface between the first buttress and thesecond buttress that is recessed below the radial height; and an inklayer adhered to the concave surface, wherein the ink layer formsalphanumeric characters that provide information related to the opticalcable.
 2. The optical cable of claim 1, wherein the concave surface hasa radius of curvature between 3 millimeters and 10 millimeters.
 3. Theoptical cable of claim 2, wherein the radius of curvature is between 4millimeters and 6 millimeters.
 4. The optical cable of claim 1, whereinthe first buttress and the second buttress are substantially parallel.5. The optical cable of claim 4, further comprising an array of groovesformed on the outer surface of the cable body in the trough.
 6. Theoptical cable of claim 1, wherein the first buttress has a first peakand the second buttress has a second peak, the distance between thefirst peak and the second peak defining a first width, wherein the inklayer defines an ink layer width, and wherein the first width is between105% and 150% of the ink layer width.
 7. The optical cable of claim 6,wherein the first width is between 110% and 130% of the ink layer width.8. The optical cable of claim 6, wherein a length of the first width isbetween 3 millimeters and 5 millimeters.
 9. The optical cable of claim6, wherein the profile feature defines a profile depth from a lowestpoint in the trough to the radial height, wherein the first width isbetween 5 times and 25 times the profile depth.
 10. The optical cable ofclaim 9, wherein the first width is between 10 times and 20 times theprofile depth.
 11. The optical cable of claim 1, wherein the cable bodycomprises a jacket formed from an extruded polymer material, wherein thejacket has a thickness between 0.5 and 5.0 millimeters.
 12. The opticalcable of claim 1, wherein the ink layer has a thickness of between 0.5and 10 micrometers.
 13. The optical cable of claim 5, wherein thegrooves of the array are positioned in a non-parallel position relativeto a longitudinal axis of the cable body.
 14. The optical cable of claim13, wherein the grooves of the array are substantially parallel to eachother and are substantially perpendicular to the longitudinal axis ofthe cable body.
 15. The optical cable of claim 1, wherein the ink layeris a surface-applied ink layer located on the outer surface of the cablebody as opposed to embedded below the outer surface of the cable body,and wherein the ink extends outward from an outer surface of the profilefeature.
 16. The optical cable of claim 11, wherein the jacket comprisesa non-polar material that does not readily accept bonding of charged inkdroplets.
 17. The optical cable of claim 1, wherein the profile featureis not formed around the entire perimeter of the cable body, whereby theprofile feature facilitates tactile identification of the ink layer. 18.A method of forming an optical cable with a print protecting outersurface, the method comprising steps of: extruding a cable body tosurround an optical fiber, the cable body having an outer surface;forming a profile feature on the outer surface of the cable body,wherein the profile feature comprises a trough that extendslongitudinally between a first buttress and a second buttress, the firstbuttress and the second buttress having a radial height, and wherein thetrough defines a continuous concave surface between the first buttressand the second buttress that is recessed below the radial height, andapplying an ink layer forming indicia on the profile feature.
 19. Themethod of claim 18, wherein the outer surface of the cable body isheated prior to forming the profile feature.
 20. The method of claim 18,wherein the profile feature results in the outer surface of the cablebody being asymmetrical about a plane along a longitudinal axis of thecable body.